Document NEYyz5VMdxrxdQ6zgXLBbZ8mR

THE VOICE OF AN INDUSTRY \AM e think there is a moral for all of us in the following story: Recent failures of electrical cables in the New Nork City area were discussed on the evening television newscasts of both NBC and CBS. A piece of lead sheathed cable was displayed by the sci ence editor and lead was blamed for the power failure. It was allegedly produced by corrosion effected by salt used for snow control. One of our staff dug into the story and this is what he discovered. The util ity reported the cables in question were 30 to 40 years old. Their record of ser vice was so admirable that replacement cable will be similarly lead sheathed. Negatives make news. The amateur pottery maker's defective ceramics; slumconnected child poisoning--these rein force the negative associations of lead. That is why this magazine is dedi cated to accentuating the positive: im proved environment created by noise suppression, enhanced industrial person nel relations brought about by lead bat teries, highway safety abetted by chrome yellow. It's an uphill fight. But worth making. \ our comments and suggestions are wel comed by the editorial staff of LEAD. D. Broward Craig, / President ' Lead Industries Association LI^6646 'i \ N 1. 1 ra E II a P th te N l ti (r it t c ent er set s bec o r d s in s pec if ic at io n o f LEAD The World Trade Center, located on a live-acre site near the tip of Man hattan overlooking the Hudson River, ha5 changed the profile of New York's .arid-famous skyscraper skyline. The enter, which is designed by Minoru Yamasaki and Associates of Troy, Mich.; and Emery Roth and Sons of New York City, is dominated by the world's tallest buildings. They are the 1.350 feet high twin towers that soar 110 stories into the sky and they are rapidly becoming as well known as the Empire State Building, which they exeed in height by 100 feet. Opened for business in December, 1970, the Center is designed to expand he flow of international trade by bring ing together business and government agencies involved in the marketing and processing of such trade. Housed within Ae five commercial buildings at the Cen ter--the twin towers, the Southeast and Northeast Plaza Buildings and the Lnited States Customs Building--will all the financing, transportation, com munications and trade education facili;ies required to carry on international made as efficiently as possible. When the Center is completed in 1974, l( will contain 9 million square feet of ffice space and have a daily population about 50,000 workers and approxi mately 80,000 visitors. A hotel, the first l0 be built in lower Manhattan, is sched uled to be constructed at the Center. Built by The Port Authority of New York and New Jersey at a cost of about $700 million, the World Trade Center is on such a gigantic scale that its con struction is resulting in an impressive list of record-breaking achievements. FOUR RECORD USES OF LEAD For example, by the time the Center is completed, nearly a million pounds of sheet lead will have been installed. While the nearly one million pounds of lead is a record for this tvpe of con struction, three other record uses of lead also are expected to result by the time the Center is completed. They include: The most lead used to line land scaping planters . . . about 780,000 lbs. The most lead used to waterproof a water fountain . . . about 60,000 lbs. The most lead used to flash the base of buildings . . . about 54,000 lbs. Most of the lead is being installed in and around the World Trade Center Plaza, an enormous five-acre elevated platform that will surround the six build ings at the Center. For example, 20 huge lead-lined land scaping planters are being installed around, adjacent to, and between the six buildings facing the elevated plaza. Also being installed is the lead flashing around the base of buildings facing the Plaza as is the lead waterproofing for the water fountain, an enormous installation located in the Plaza's gigantic 369' by 375' Center Court. Installation is yet to begin for two additional lead applications that will be added to those now being installed; lin ing for 30 large sidewalk-level landscap- LIA 26647 3 ing planters, and waterproofing for ex terior stairways leading from the street levels i the Center is surrounded by Church, Liberty, Vesev and West Streets i to the Plaza and from the Plaza to the Center's Concourse Level, located immediately below the Plaza. Installation of the lead waterproofing for the plaza-level landscaping planters, the water fountain and flashing for the perimeter of buildings facing the Plaza has been underway since early this year. The lead is being installed through a joint venture sub-contract shared by John F. Abernethy & Co., Inc., Brook lyn, N.Y.; and Allied Lead, Inc., Chi cago. Lead for the three jobs is being sup plied in increments depending on con struction schedules of other sub-contrac tors working on the World Trade Center construction project. Both 6 lb. psf 13/32" thick) and 8 lb. pounds per square foot Cg" thick) lead is being used. The lead contains not less than 3:!4 percent nor more than 4J4 percent antimony and an arsenic content of 0.10 percent to provide for increased corro sion resistance and to decrease thermal expansion. Sheet sizes as large as prac ticable are being utilized in order to keep joints to a minimum and thereby help insure the watertight integrity of the lead. Lead's corrosion resistance, freedom from maintenance, and the fact that it provides for a trouble-free waterproof ing membrance are the primary reasons it was selected for the various moisture protection applications at the World Trade Center. Lead's traditional dura bility--it will invariably outlast other building materials when properlv in stalled--was another important selection factor. All sheet lead to be in contact with concrete, fill, mortar or grout is pro tected first with a cold-applied bitumi nous brush coating of 12 to 14 mil thickness, a normal precaution against potential corrosive attack from free lime found in all materials containing cement. To insure that the lead mem brane is protected from possible damage by sharp-edged stones and other inclu sions in the cement, a 30 lb. asphaltimpregnated felt covering was applied over the bituminous coating before the sheet lead was installed. PLAZA-LEVEL PLANTERS Typical of the critical role lead is playing in constructing the Center is its use to line the 20 plaza-level landscaping planters. Simply stated, the lead lining for the planters is an extension of, and is incorporated with, the multi-mem brane moisture protection system that is being used to waterproof the entire fiveacre Plaza area. The system serves as the roof for the Concourse Level and must be made completely moisture-proof in order to insure that various faci|. ties therein . . . shops, restaurants, et(; . . . are not damaged bv water leakin through the roof. The landscaping planters will be 0ne of the major highlights of the Pla;j area. In addition to their landscape function, they will help break up thj distance between buildings and tht Plaza area, separate building sides fi0rB street areas, and serve as dividers be. tween buildings and the Plaza's Center Court. Some of the planters will be jj big as 106' long and 40' wide while others are nearly a block long and about 6' wide. The large landscaping planters nil) contain 6 London plane trees, each with an approximate 12' branch diameter; about 7 flowing crab apple trees: and more than 1,400 evergreens. About 1,190 plantings of Baltic ivy will be used to fill in the outer edges of the planters. The tallest trees will be planted atop 1 series of "hills", some as high as sir feet, which will be created within the planters. SIDEWALK PLANTERS The lead lining for the 30 street-level landscaping planters, like the lining for the 20 huge plaza-level planters, also plays a vitally important moisture pro-1 Overall view of Center Court water fountain unQer construction. ,,i0n role. Each 10' in diameter and [ut;ell 5' and 6' deep, the planters will bur ie!ed in sidewalks running alona entire block fronting on Church ,,,reet and partly along Yesey and Libftv Streets. Part of the Center's Conjur-e Level as well as subway station facilitie.s are located below the sidewalks >d therefore the planters must be thorj,lv waterproofed. London plane also will be planted in the side- ,alk planters. w a t er p r o o f in g p l a z a -l e v e l b u il d in g p e r ime t e r In designing the moisture protection ,v-;em for the orld Trade Center's live-acre Plaza area, particular attention ,,aj paid to insuring that a watertight .fal was installed around the plaza-level r-xterior perimeter of the Center's five commercial buildings and the proposed hotel. The reason: all the buildings will extend through and above the Plaza in much the same manner as gigantic thruroof penetrations and a failure anywhere along the seal will likely result in water leaking into the scores of international -hops, restaurants, between-building pas-ageways and other facilities in the Con course level. SHEET LEAD USED TO FLASH BASE OF PLAZA-LEVEL BUILDINGS Waterproofing around the perimeter of the buildings is being accomplished with sheet lead and, like the sheet lead mem brane used to waterproof the plaza-level landscaping planters, it is being joined tem in order to insure that the entire five-acre area is waterproof. Nearly everything at the World Trade Center is on a gigantic scale and instal lation of the waterproofing around the plaza-level perimeter of the buildings is no exception. For example, more than half a mile of 3' wide sheet lead has al ready been installed around the perim eter of three buildings at the Center. Included in the total are 840 lineal feet of sheet lead for the perimeter of each of the twin towers and approximately 1,109 linear feet of sheet lead for the perim eter of the Northeast Plaza Building. 17-TON ROTATING CENTER COURT FOUNTAIN TO BE SET ON HUGE PLATFORM Among the many dramatic sights at the World Trade Center will be the water fountain in the Plaza's center court. The fountain is believed to be the biggest of its kind ever built. A 21' high, 17-ton cast bronze sculp ture. to be set on a 13' diameter rotating turntable, will be installed in the center of the fountain. A circular platform with an outside diameter of 82' 4" will sur round the large rotating turntable on which the sculpture will be set. Rising from a 4' base, the platform, which has been completed, gradually slopes up ward to the point where it adjoins the circular turntable. Water flowing from the rotating sculpture at a flow rate of 7.600 gpm. will cascade over the sur face of the circular platform that sur rounds it. be collected in a gutter at the platform base, and then be recircu lated through the sculpture by a large charge chamber located in a well below the fountain. Approximately 76,000 square feet of sheet lead was used to waterproof the fountain and the 30 sq. ft. charge chamber well below the foun tain. Six lb. psf sheet lead was used to waterproof the top of the rotating turn table and the platform surrounding it while 81b. psf sheet lead was used to waterproof the charge chamber well. A total of nearly 30 tons of sheet lead was required to waterproof the fountain which, like other plaza-level installations, is located above the Concourse level. The 13' diameter rotating turntable and the 82' 4" diameter platform sur rounding it will be covered in black granite. Until this is accomplished, the lead membrane covering the turntable and platform has been painted white to reflect radiant heat from the sun and thus avoid possible damage from exces sive thermal expansion. The huge size of the fountain is architecturally scaled to compensate for the gigantic propor tions of the 369' x 375' center court. he substitution of a lead acid batterv" powered lift truck for one powered bv a propane fueled internal combustion engine has solved a number of perplex ing corrosion and environmental prob lems at Aberdeen Tricot. Inc., a knitting company in Aberdeen. N.C. Company president. Glenn Fogleman. reports that the following facts became evident soon after his plant began op erating: Knitting needles, machinery parts and other plant equipment were rusting. Expensive maintenance and parts replacements were required to keep the plant operating. A few employees were suffering from minor nausea and minor eye irritations. Production and sales were decreas ing due to equipment downtime and a loss in productive manhours. The solution to the problems, all of which were found to be related to the use of a propane-fueled lift truck, is an interesting case history of a search for the source and effects of pollutants that .can develop under certain conditions in the controlled atmosphere of an indus trial plant. Closely controlled temperature and humidity conditions are critical require ments for the production of quality tri cot fabric. At Aberdeen Tricot, the tem perature is kept at 78 to 80 F. Humidi fiers automatically maintain a relative humidity of 58 percent. The temperature and humidity, com bined with exhaust fumes from a pro pane-fueled fork lift truck, were first thought to be causing the corrosion, eye irritation and nausea problems since they were most evident in the produc tion area of the plant where the truck operated. Steps were therefore taken to replace the truck's carburetor, tune the engine, and change the fuel tanks, think ing that somf foreign elements may have been placed in the tanks. These preventive measures produced no effect and the problems continued to worsen. The corrosive conditions, evi dent in formations on door latches and other plant equipment, became critical when they developed on the hundreds of delicate knitting needles attached to the 14-foot long needle bars of about half of the 14 knitting machines in the plant. The corrosive attacks were par ticularly aggressive when the machines were stopped to change a knitting pat tern. The needles became corroded be fore the knitting operation could begin again. Corroded needles prevent yarn from traveling through the knitting zone. An estimated S5,000 was spent to re place rusting needles during a two month period. In addition, production time was also lost due to machinery downtime re quired to change the needles. With these combined factors becom ing more and more detrimental to plant production and sales volume, as well as employee health and morale, the com pany president searched for other solu tions to the problems. For example, he thought the plant's electric duct heaters, used during winter months to heat incoming air to keep the plant interior at a constant temperature, might be the cause of the problem. His conclusion was arrived at after a num ber of related circumstances were considered. The knitting machines in the plant also are kept at a constant temperature To accomplish this, a coolant oil is circulated at the base of each knitting ma. chine. A small amount of this oil is va. porized and the resulting vapor con. denses on the cooler overhead structure including the air conditioning and heat ing ducts. The heating elements were in vestigated and. since visible traces oi the condensed oil were found, it wait presumed that some of the particles were! being burned when they came in contact with the energized heating elements. This was thought to result in fumes th were causing the corrosion and enviro mental health problems and this theo was strengthened by the fact that company president detected what thought was smoke coming from the a vent in his office during those times wh the heating elements were energized. As the result of this theory, Aberde Tricot president Fogleman requested sistance from Carolina Power & Li Co. to solve what was thought to be problem with the plant's electrical he ing system. Their representatives ma a careful study of the plant's air h' dling equipment, determined it ' working efficiently, and believed it w not causing the corrosion and enviro mental health problems. Since the problem only existed in 6 LI A26650 T pr o d u c t io n pr o bl em Close-up of knitting machines at Aberdeen Tricot. Pencil indicates small size of delicate knitting needles seen in section ot 74' long needle bar used on knitting machines. judion area and not in the adjoinP|jnt office. Carolina Power & Light '`^ntati'es turned their attention to first believed to be the source ^ihe problems: the propane-fueled lift They speculated that fumes ^,itfd from lhe truck operating in the environment of the plant projn abnormally high concentra ted nitrogen in the atmosphere. When & nilrosen was mixed with the tvater ll(,,r continuously circulated by the .miditiers, and then combined with the *uird air during u inter months, the -itotrtt caused a chemical reaction that ~Jlrd in the formation of nitric acid - m hieh is highly corrosive to most vik rbe utility company representatives i.<u concluded that the nitric acid mist UM * J> the pollutant that ultimately ud the nausea and eye irritation. "Sr felt that these two environmental .V,clems were caused by the two nitric sid-based poisonous gases: nitric oxar. hich is formed when nitric acid mbtnes with metal; and nitrogen di oxide, which is formed when nitric ox ide combines with oxygen. The situation at Aberdeen Tricot was unique because the nitrogen dioxide was reacting with the presence of moisture in the atmo sphere to form more nitric acid, thus generating a continuous cycle of highly corrosive and toxic conditions as long as the heating season lasted. Carolina Power & Light representatives therefore recommended that an electric fork lift truck replace the propane fueled vehicle. Wishing to prove their theories and to insure Aberdeen Tricot that their opinions were unbiased I the electric company promotes the use of batterypowered electrics in industrial plants because they are normally recharged during off-peak hours), the Carolina Power & Light representatives assisted Aberdeen Tricot in studying the corro sion and environmental problems. Samples of the oily mist and rust from the plant equipment were taken to be chemically analyzed by an outside chem ical laboratory. The tests showed that about 9.5 ppm nitric acid was present in the air in the knitting room. fumes being emitted into the air of the knitting room. They were therefore as sured that the presence of sulfuric acid fumes, plus nitric acid fumes, could promote the high rate of machinery rusting. Based on this combined evidence. Ab erdeen Tricot president Fogleman or dered a lead acid battery-powered fork lift truck as a replacement for the pro pane-fueled vehicle. During the 18 months the lead acid battery-powered fork lift truck has been in operation, the plant has experienced no noticeable cor rosion action and there have been no Meanwhile, the corrosion rate of the further incidents of nausea or eye irrita knitting needles was being observed. In tion. this phase of the test, needles attached to The electric truck used at Aberdeen tapes were placed on knitting machines Tricot has a 4000-lb. capacity. It is fitted throughout the plant. Needles placed with a long pole when used to move near where the fork lift truck operated wrapped circular rolls of cloth onto rusted in three hours while those at the trucks at the loading dock or to unload rear of the building, and some distance bundles of hollow cores which are used from where the truck operated, rusted to wrap the rolls of cloth. To move the in 18 hours. While this also tended to circular rolls of cloth or bundles of prove the propane fuel fork lift truck cores, the pole is inserted in a core and theory, it was felt that the test was in is used to lift the material to be trans conclusive because of the difference in ported. When huge spools of yarn, called conditions at the front and rear of the beams, are to be moved into the plant plant. or to and from the knitting machines, The problem was also discussed with the long pole is replaced with two forks. a staff member of the North Carolina Based on the successful use of the State Industrial Extension Service and electric truck at the Aberdeen plant, an it was learned that propane can contain other one was ordered for a new 38.000 sulfur which can be oxidized in the sq. ft. plant that Mr. Fogleman manages the truck engine and result in sulfuric acid j ust across the street. Glenn Fogleman, Aberdeen Tricot President (left) and J. David Smith (right), Industrial Power Engi neer, Carolina Power 4 Light Co., discuss opera tion ot knitting machines. LIA2665 1 ! CHROME YELLOW TO PLAY EXPAND I ead chromate paint will play a major cated during a two-year period beginning frequently used to prevent highway " role in tw o highway pavement mark ing programs that are key elements of a proposed nationwide. Federally-funded highway safety project. The two pro grams were developed to help decrease the staggering 16. I million \ehicular traffic accidents that resulted in 55 thou-and deaths. 2 million disabling injuries and more than Sir billion in property damage in the L niter! States during each of tile [last tw o v ears. w ith the fiscal year ending June 30, 1974, would be authorized for the program. The second project authorized by the Act would be a pavement-marking re search and demonstration program to de termine the effectiveness of various types of pavement markings under inclement weather and nighttime conditions. A total of 350 million would be authorized lor (his phase, funding for the program also would he available during the two- fic accidents. They indicate "passinJJ "no passing" and "passing-w'ith-cauti0t|i3 zones and, even though they are know.1 as center lane markings, they are always in the geographic center of pav 1 meats. Solid line pavement marki^I also are used to mark the pavement of Greets and highways where there js inadequate clear space to the left o( ^ line even for disabled vehicles or f0 making emergency stops. The nationu ide highway safety project year period beginning with the end of These tvpes of pavement marking, would result from the Highway Safety the 197 1 fiscal year. and others such as curb markings and Act of 1975. which is expected to be Such traffir control devices can pre transverse line' to indicate highway <4 passed earlv in the next Congress. The vent thousands of accidents and subse structions are painted "highway vellow" two highway pavement marking pro quent deaths, injuries and property dam a special color standard that has been grams. which will cost a combined 3250 age annually. It is estimated that the specified for all cautionary highway tra) million, are considered of priority from pavement marking programs can save fic control device* including signs. among the more than a dozen highway from 3,000 to 5,000 lives and avoid yellow paint pigment that most readily j safety programs to he authorized by the from 63,000 to 105,000 injuries each meets this standard color requirement ,, ; Act. Two thirds of the more than SI bil year in the Lnited States. It also is esti well as cost requirements is lead chrom. ' lion annual cost of the highway safety program would come from the Highway mated that such pavement markings will save 32.5 to 34 for each dollar it will ate, or "chrome yellow" paint. Yellow : is the most visible color to the human Trust Fund, which is financed by Fed cost to apply the pavement markings. eye from among all those in the color eral taxes on the sale of oil. gasoline and The difference in numerical and dollar spectrum. truck highway uses and can now only be figures is due to the fact that Federal, In addition to meeting the color stan i used for new Federal-aid highway con struction. State, urban and rural roads each have different highway accident rates: Rural dard for highway vellow, chrome yellow paint possesses many other important roads, for example, accounted for a qualities which make it the most very, The first project authorized by the Act whopping 68bf of the highway traffic tile, low-cost pigment available for traf. would be a special pavempnt marking deaths during the 1971 period. It is for fic control devices. Chrome yellow pair* program. It will meet the critical need this reason that the special pavement also has good resistance to degradation to provide, for the first time, sufficient initial funds to thoroughly mark those marking program authorized by the Act gives priority for installing pavement by light and it resists chemicals used to remove snow and ire from pavements. rural two-lane roads where two-thirds of the nation's highway fatalities presently oi'cur. A total of 3200 million, to be allo markings on rural roads. Solid, broken and dotted single and double center line markings are the most It is for these reasons that chrome vel low paint will play a major role in anr nationwide highway pavement marking DECREASING t r a f f ic a c c id e n t s : i 1 1 1 -| ,jrn Jn most rases. reflectorized U'1-' \ yellow paint will he Used for the 1 'rment markings since it is important '^Vihey he highly visible at night. ! jiie $200 million the Act w ill allocate ,he nationwide highway pavement program cannot he fully appre- " rtcd until one 's aware i the critical ' j for such a program. Simply stated. t ill proside, for the first time, funding mark in accordance with the 1971 'ilnuial on Uniform Traffic Control De|(',.s for street and Highw ays i known the LTCDi those roads which are in' hided in the Federal-aid primary and undarv highway system as well as 1,,-^e roads which are not. p revised, updated and expanded ver-ion of the 1961 UTCD it supersedes. ^ 1971 edition is published by the US. Department of Transportation, Fed eral Highway Administration, and was developed with the cooperation of the National Joint Committee of Uniform Traffic Control Devices. The end result of efforts that began in 1927 to develop uniform standards for traffic control deiices, the 1971 Manual is intended to serve as the regulatory directive for all streets and highways in the United states. There is. however, a major problem in implementing and complying with the new manual on a nationwide basis until the new law is passed. To under-tand the problem, it is necessary to have a basic understanding of the United states highway system, how it was built. and how it is being maintained. Of the nearlv I.OHO.IMHI miles of paved street' and highways in the 1 nited States, only 900.00(1 miles of late rstate. State and rrmntv and municipa J pri mary and secondary roads are htii It with Federal aid funds. In qualifying for such hichwav s built w ith Federal-aid funds, indiv idual States were t ommitted to maintaining: them after they were built. They had t- n do so in accordance with instructions a nd reg ulations established by the l TC! D Man ual. Hard pressed for fund? nei eded to comply even w ith the 1961 rdi ition of the Manual, the Stales found it \ irtuallv impossible to enmplv with the greatly expanded requirements for the ii icreased use of traffic control devices oul tlined in the 1971 Manual, In particul ar, they lacked the funds to provide tl te paint, men and equipment needed to, comply with the new requirements. For example, the New Vo ,rfc State Highway Department expects, to use about 7,08,000 gallons of highw ay yellow paint this fiscal year when it h egins im plementing the provision of the new Manual. The Department esl imates it will require an additional IT 2.000 gal lons of highway yellow paim t to fully comply with the new Manual t luring the 1978 fiscal year. It takes aho ut 17 gal lons of paint to paint one r uile of 1" to 6" wide normal width pavement marking; the State expects to have to paint approximately 20.000 miles of additional vcllow pavement marking to comply with the new Manual. Many municipal and county officials, responsible f ar maintaining the nearlv 8.000,000 miles of paved rural and ur ban primarv and secondary highways that were not built with Federal aid funds, find it difficult if not im;* issihle to comply with the guidelines published in the new Manual. Ibex have far less funds to allocate for -uch pur]H-s,es than do States, and. as a result, tiiv 27'. of such highways have ie-en marked m accordance with the Manual. With t!>e $20t_t million likely to be al located hv the Highway Act of 197 b it is expected that States and counties in the l nited States will hav e sufficient money to provide the paint, men and equipment required to mark the principal high', ays under their respective jurisdictions, in addition, the funding will permit surrey? to determine where pavement markings are needed in order to comply with the 1971 UTCD Manual- In carrying out the program, it is es timated that 7)00.000 miles of two-lane roads w ill receive yellow- centerline mark ings and the approximate cost will hr $40 million. It is expected that $25 mil lion w ill he spent in applying "no pass ing" pavement markings, and approxi mately 500,000 miles of edgelme? w ill he placed on primary and secondary county and township routes at a cost of 31.85 million. LEAD CLAD STE1EL FOR ARCHITECTURAL USE Anew rompfltrite material that com bines lead's outstanding corrosion The d(? velopment of lead clad steel for tank pc inels is of particular importance resistance, aesthetic appeal and sound -ince si teet lead alreadv is being used barrier properties with the strength of to line a variety of chemical and pollu rteei has been -ueressfuIlT introduced in tion co i atrol vessels. The availability of fin al Britain. a mate:r ial that can easily be fabricated Called lead clad steeL the new com to form an economical lead-lined vessel posite material was developed by the is then) fore expected to result in ex British Non-Ferrous Metals Research panded lead uses for such applications. Nseociation. it is produced by pressure Beca' i sc lead coated steel combines -...H..tirio lead to -trs-[ sheets which hate le ad's on tstanding advantages as a sound beep pre-coated with lead alloy. The lead barrier material with the strength of clad -teei has been subjected to exten- steel, it i s ideally suited to meet the in- -ive mechanical and thenna.' testing rreasinsr demands for quieter commer without bond failure. It is easy to fabri cial. ind i istrial and consumer products. cate and has already been successfully Topical potential applications include used for eommerciaj and industrial enclosures for home appliance equip rmiidms: construction application in ment such as dishwashers, waste food i Ireat Britain. disposals and laundry equipment; duct \merican lead producers have ex work for air. liquid and semi-solid han pressed an interest in producing the new dling svstterns: industrial machinery and lead clad steel for the domestic market because the composite material offers an equipment enclosures: and a variety of automotive transportation equipment excellent potential for increasing the uses. In [ i articular, the use of lead clad lead market in the Lnited States. steel can assist the producers of com LEAD PRODUCT APPLICATIONS EXPANDED Lead clad steel has made it possible to specify the material at prices that are mercial atnd industrial machinery and equipment in complying with Occupa tional Saf ety and Health Act lOSHA) regulation!!. competitiye with other quality metal products used in the construction mar BOTH SMtCiLE AND DOUBLE SIDE CLADDING AVAILABLE ket. an existing important domestic lead Lead cbtd steel is currently being pro market. Some examples include such duced in sdieet form in the United King uses as fasetas and wall coverings, appli dom. Both single (one side) and double cations that have already been devel i both sides ) cladding are available. Sin oped in England, and for applications gle cladding is immediately available such as roof coverings, ventilating ducts while doo!>1e cladding is produced on and equipment, gutters, rainwater pipes a special or < ler basis. i downspouts) and parapet coverings. Heretofo re. it was sometimes not practi cal to use lead for such applications be cause it normally requires structural support which, in this case, the steel cladding supplies. However, an even bigger market is believed to exist for commercial and industrial applications of lead clad steel Single si lie cladding is being produced with lead co atings that range from .020in. to .040-in. applied to steel that ranges in thickness from 14 to 16 gage. The standard mtminal coating for building applications ranges from ,020-in. to .030in. thickness s of lead bonded to 20 gage steel. Thick*-r lead coatings on steel are being exploited for chemical applications. and such applications are now being ex plored by British producers. These ap FABRICATORLEAD CLAD STEEL plications include panels and smaiL deep- Standard iroll-forming, brake-pressing, drawn containers from sheet as well as lock-forming and deep-drawing metal Hanged duct sections and spirally working teei uniques can be used to fabri wrapped tubing formed from strips. cate lead ch *1 steel. However, as is the case with most new materials, Son,( i minor initial tooling modification niaT be required to accommodate the forming j characteristics of the composite material Standard hand and machine tools also can he used to fabricate lead clad stee) and, in addition, drilling, punching anj cutting operations can be easily per formed. Lead clad steel can he bent through 180 without loss of adhesion and, although some thinning of the lead occurs where it forms the outer surface of the bend, the local reduction in thick ness is normally acceptable. Most types of fasteners can be used to mechanically join lead coated steel When decorative architectural panels are secured to timber battens or other structural members, lead capping pieces i can be incorporated to provide a con- j tinuous lead surface. The use of lead capping pieces also helps to waterproof the fastener and retain the pleasing ap. pearance of lead throughout. With certain limitations, lead burn, ing and soldering can be performed on lead clad steel almost as easily as when using sheet lead. W'elding the steel sec- tion of the composite material will de- stroy the lead coating in the heat af fected zone of the weld and therefore requires special care. However, stud and projection welding can be used to pro duce satisfactory joints; similarly me- chanical fasteners can be attached bp these methods without detriment to the lead coating. A strippable, self-adhesive paper coat ing is applied over the lead cladding to * protect it during fabricating, shipping | and installation. After installation, any \ exposed edges of lead clad steel can be ` sealed from corrosion attack by paint-1 ing with quick-drying primer followed f by a coat of finish paint. Alternatively ( exposed edges of lead clad steel can be > protected by tinning, a method that iri particularly suitable for double clad 4 sheet. : ROOF FASCIA IS FIRST LEAD CLAD > STEEL APPLICATION j The first application in England for lead coated steel was the roof fascia of# i i LIA26654 10 0,,.,haped National Mutual i!W'e"' \,Hon of Australasia Ltd. ofL'VTli.u' de^ued by Goto h & Part>r blJ, ated m the Citv of Lndon '"'o Lthe precinct of St. Paul's Lathed- 'i:!un neW office buildinst. like the rji'rK;/J1nous cathedral, has a lead roof. ' The faicia of the roof of the six-story ` u:nJ u in the form of an open o'''1":!!;,',,.;! u ' r';uCjh -tailed and I1"' \erticallv u'de. the panels are around the fascia of [ .(hich. like the building itself, .`aaonal in shape. A small gap sep arates each of the panels and they are hung with stainless steel bolts. Because the backs of the panels are partially ex posed to the weather, lead cladding was applied to both sides of the panels. They were fabricated from 20 gage terne-plate steel with a coating of about Mb pounds per sq. ft. 1.0234" thick I on each side. OTHER LEAD CLAD STEEL APPLICATIONS Architects .Newman. Levison and Part ners also used the newly deyeloped lead clad steel for the new buildings they designed for the Road Transport Indus try Training Center Board's Multioccupational Training and Educational Cen ter 1MOTEC1. located at Livingston New Town, West Lothian. They used the lead steel composite material for the facia of the MOTEC Conference Hall and for several applications on the boiler house that provides heat for the facility. fn addition, the lead clad steel was used for \arious other applications at the MOTEC facility. The applications included window fascia for dormitory buildings and siding and roof fascia for a restaurant. ^ose-uo view of new National Mutual Life Association ot Australasia Ltd. building in London, England, shows how lead clad steel was used tor 200 vertical panels ha! make up fascia tor roof of bui/ding. at left shows how lead clad steel panels were used lor window fascia of a residential building at the MOTEC facility located at Livingston New Town. View at 'Sfff shows how panels also were used for window fascia ot another residential building (seen at tar left) and the siding and root fascia of an adjoining restaurant *eeft in cfose'Up at cental right). NOISE POLLUTION SO^ APARTMENT COMPLEX FINDS SOUNDPROOFING PROFITABLE Suppose vou spent considerable time. effort and money to build a group of architecturally impressive townhouse apartments, installed a fireplace in each apartment and furnished it in excel lent taste: land-raped the surrounding grounds in keeping with the quiet, countrv-like setting of the area, and then dis covered that vi h i couldn't keep the apart ments occupied because tenants com plained of excessive noise. Sidney Rolfe. a successful Manhattan economist, faced this problem when he built the first of three apartment build ings he owns in the popular resort area of East Hampton. Long Island. Known as Hampton Mews, the buildings each contained a row of eight connected twostorv units. Each unit contains two apartments--a floor-through apartment at ground level: and a second-story du plex apartment that is reached via an outside stairway between each apartment. The noise problems w.-re encountered when tenants began occupying the first apartment building at Hampton Mews. Thev were being caused by a number of factors, none of which were thought to result in sound attenuation deficiencies when the first unit was built. The wood structural system used to construct the apartment huilding and the materials used for the floor of the second-story duplex apartments resulted in the creation of a drumhead that stretched across the entire second floor area of the 16 apartments in the build ing. The drumhead effect magnified the slightest sound. Normal conversation and the sounds of radio and television were clearly audible between the ground floor and second-story apartments. Walk ing across the living room of a secondstory duplex apartment in the building while wearing high-heel shoes was com pared to the sound of blows from a ham mer and even the normally barely audi ble sound of a small plastic ball being rolled across the second floor by a play ful cat sounded like hurling a ball down a bowling alley. The building owner re ports that primarily due to such noise problems, five of the first 16 tenants in the apartment building moved during the first year it was occupied. To correct the sound attenuation prob lems, the owner retained the services Partial view ot first unit of apartments Duitt at Hamp ton Mews. Carpet folded Pack :n bedroom to show sheet lead sound barrier. View ot living room in typical duplex apartment where carpet covers sheet lead sound barrier. \\u of M. J. Kodaras & Associates, an El^ hurst, N.Y., firm specializing in acous. tical consulting. As the first step in solving the sound attenuation problems, the acoustical specialists tested the noise level trans. mission of second-story flooring in the apartments. It consisted of one lavet 1U3;/' thick dense fiberboar d with ply. wood underlayment on 2 x 8" joists with a 4" thick glass fiber blanket be. tween joists and a thick gypsum board finished ceiling below. Results of the tests showed that thf floor construction had a Sound Trans, mission Class iSTCi of 34. a level a| which loud speech is clearly audible. In order to increase the STC to an acceptable level, consideration was given , to applying various combinations of ma. terials to the ceiling side of the flooring > but this would have been expensive anti time consuming. According to Steven Wolf, the M. J. Kodaras & Associates acoustics engineer who supervised the materials study, it became evident that the required acoustical improvements could be achieved most quickly and eco nomically by installing 3 lbs. psf i 3 64" thick) sheet lead over the entire second- story floor side of each apartment except for kitchen and bathroom areas. Installation of the sheet lead sound barrier was so simple that it was accom plished by a member of the Hampton Mews maintenance staff. The only equip ment required was a hoist, which was used to lift some of the lead rolls to the second floor, and a cutting tool. After the lead sheet barrier was in stalled, the flooring achieved a Sound; Transmission Class of 39, a five decibel increase in sound transmission loss. Ac cording to M. J. Kodaras & Associates, this is considered to be a substantial improvement in sound loss. At this level, loud noise is barely audible. Speaking of the effectiveness of the sheet lead sound barrier, owner-builder Rolfe stated: "Lead literally saved the - building. Lead was the most economical! and quickest solution to the problem^ and there have been no noise complaintH from any apartment in the building." He? also said that the cost of installing thf| lead was quickly amortized by the fulltf rented apartments in the building. { 12 LIA26656  p,VERSE a p p l ic a t io n s g a s COMPRESSION STATION PRACTICES GOOD NEIGHBOR POLICY high-pitched whine uf turbine | iumpressors--comparable in sound ir,t airplane--arc necessary to keep ,t0H irig through cross-country pipe- but thev are hardly endearing * fi,frn,, .-rieuns- hideinnstitaalllaatiroenass. must This be located was the p.pm faced by two Canadian natural . einipanies when they each needed to t:,j 4U,-h a gas compressor station. Wi-hing t be good neighbors, the , utilities were determined to find a ' JV ,f decreasing the 115 decibel i db t ...and of the turbines to an acceptable ,,vt,| that would not disturb residents of V communities where the gas com- ressoc stations were to be constructed. yhe two companies concerned with the noise problems w ere the Ontario Di,ibon of Northern and Central Gas Corrotation Ltd., and the L nion Gas Com.,jnv of Canada Ltd. .Northern and Cen tal planned construction of a compres,or station powered by two 1.100 H.P. turbines at Hagar, near the city of Sudmrv in northern Ontario. Lnion Gas planned a slightly larger installation at hobo. near London. Ontario, that would powered by a 12.500 H.P. turbine. Rather than be concerned with the arise problems after the two compressor cations were built, the two companies oined forces to solve them as the sta tions were being designed, ft developed that it was not only possible to decrease the sound of the turbines to acceptable levels, but a new composite acoustical building was created to accomplish the job. The gas companies selected Interna tional Pipeline Engineering. Ltd. IPEL), a subsidiary of Trans Canada Pipelines Ltd., to act as consultants in designing the stations. Included in the agreement was a requirement to solve the noise problems. Aware of similar noise levels encoun tered at other compressor stations built adjacent to residential areas, IPEL drew up rigid specifications for the new com pressor stations. The requirements called for noise controls to be built into the turbine equipment as well as the struc tures that would house them. Pro-Eng Buildings Ltd., Streetsville, Ont., was awarded the contract to build the compressor stations. To meet the sound specifications, Pro-Eng developed an acoustical building panel to enclose the compressor stations. The panels consist of the following components and materials: Inside face--2 lbs. psf 1.0512" thick) sheet lead bonded to the back side of 24 gage 1.0239" thick) Y-rib gal vanized steel sheet. Center core--one 4" and one 3" thick low density fiberglass layer with vinvl backing. Exterior face--26 gage t.01,9" thick i galvanized steel sheet w ith a baked enamel finish. The building panel girts (stiffeners i were cold rolled from steel Z-sections. The building panel, when tested for noise barrier quality, received a Sound Transmission Class t STC ) rating in ex cess of 40 decibels. An STC rating is a measurement of the relative efficiency of acoustical sound barriers established bv A5TM specifications E90-66T. The steel lead/ fiberglass acoustical building panel was used for both roofing and siding at the two installations. The two 1.100 H.P. turbine compressors at the Northern and Central compressor sta tion at Hagar are housed in a 30' \ 50' x 14' structure w hile the single 12.500 H.P. unit at Union Gas Corporation's Lobo installation is housed in a somewhat larger 43' x 57' \ 22' building. According to both pipeline operators and IPEL, there have been no complaints of noise from either of the installations. It is therefore expected that additional applications for the new lead, fiberglass/ steel composite material building panel will include its use in constructing fu ture cross-country oil and gas pipeline compressor stations. The panels also can be used to enclose a variety of other industrial machinery buildings and equipment where noise is a problem. i Building housing 72,500 HP turOine compressor at Union Gas Co. of Canada Ltd. station located at Lobo, Ontario. "j 3 BUCKET TRUCK GETS A LIFT OUT OF LEAD 1 "The nation's first truck-mounted aerial " lift bucket with a hvdraulic lift mechanism that can be powered bv lead acid batteries now in production. I se of the batteries replaces the truck en gine as the power source for the hvdrau lic lift mechanism. Called Power Pack, the newly devel oped lead acid battery power system pro vides four major advantages that result in dramatic cost savings: tit elimina tion of the need to run the truck engine to supply power for the hydraulic lift system. 12 i longer engine life. l.3l de creased truck operation costs, and i 4 ' decrease engine maintenance costs. Trucks with aerial lift devices, com monly called bucket trucks, sometimes are known as cherry pickers or lift bas kets. The basket of such vehicles, at tached to a hinged boom, is used to hoist workmen as high as 34 feet while per forming a variety of above-ground jobs. Municipalities use bucket trucks to in stall and maintain street and traffic lights and signs: they are also used to trim trees and for a wide variety of other tasks. Telephone and electric com panies use fleets of bucket trucks to in stall, maintain and repair telephone and electrical equipment. According to the manufacturer, TelE-Lect Corp.. elimination of the require ment for an engine power take-off i PTO l unit on a bucket truck w ill be particularly meaningful for those who operate Heets of such vehicles. For ex ample. use of the batteries to supply power for the bucket's hydraulic lift mechanism will save 20,000 engine miles per year. Added to this would be a corresponding saving in gasoline and Prototype battery-powered aerial lilt bucket truck is being used here lor street light maintenance. View ot new batlery-posrerw&mfW now In production show* acid batteries used to pome ot unit. ^ 'U J \ '*> ^ > -s >\C oil as well as decreased maintenance and repair, engine wear and truck downtime. Other advantages of the battery.p0vv. ered hydraulic lift unit include: quieter operation of the unit through elimina. tion of loud truck noise, virtually p0|. lution-free operation since truck engit]e emissions are eliminated, and improved voice communication between the bucket operator and personnel on the ground who will not have to shout above the noise of the truck engine. Production of the bucket truck fof lows a successful six-month test of 5 prototype vehicle. Designed and devel. oped in cooperation with Arkansas Power & Light Co., the prototype has been undergoing tests in Hot Springs, Ark., where the utility's personnel have been using it to perform a variety of maintenance and installation work. Based on the outstanding success of the prototype, the utility has announced it Ras ordered an additional batten', powered bucket truck for delivery this year. Speaking of the reasons for his inter est in battery-powered aerial lift bucket trucks, one utility spokesman said. "Through 15 years of using hydraulic equipment, our company has found that the hydraulic lift system for the baskets consistently outlasts our truck engines. I felt sure that if the truck engine did not have to run continuously to supply power for the hydraulic lift system, then the truck life would be extended and therefore become more compatible with the life of the hydraulic lift mechan ism." He also felt that the major cost sav ings could be achieved due to decreased j requirements for gasoline, oil and en-i gine maintenance and repair. The fact! that a battery-powered unit would be] quiet and virtually pollution free and] could be more easily transferred to an-f other chassis because there would be no] PTO connections to make were other| important considerations. Mounted on the chassis of a Ford] F-500 iy2 ton truck, the standard ve-j hide used by the utility for bucket truck] service, the hydraulic lift system for the] prototype vehicle appears at first gland to be no different from the more thai 100 vehicles the utility uses for bucket truck service. However, a special boij directly behind the cab houses four 29 LIA26658 r 0.volt batteries used to power the prototy'ppee'.s hvdraulic lift system. eXrEN3SllvVEfi TESTING prototype truck was driven 7,650 ,nnileth;se durin g engine t.hi-e_ test. PTO unit AMte-*t--ers and the :instanlle_ dj batteries Provided positive evidence that operat ic the hydraulic lift svstem off the PTO unit dramatically increases engine run ning time. The hydraulic lift svstem operated front lectricitv supplied by the batteries for o4 hours during the test period. The batteries were recharged by a separate, ^nuine-powered alternator as the truck uas driven between job sites. To achieve 64 hours of operating time using the PTO unit to power the truck's hydra u lie lift mechanism, it is estimated that t he truck engine would have to run apprt > ximatelv 512 hours, or at least 10.( 100 miles. These figures are based on the f; ict that the truck engine must be cc >ntinuouslv run at an average speed of 20 mph during the time the bucket is in operation. Converted to annual esl amates, about 20,000 miles would 1 ** added to the approximately 15.300 milt si an average bucket truck is driven in a year. There'ire, at >ut 200,000 engin * miles can be saved during the averagt 10-vear life of a trurk. Equally impressivi' are saving: that are expected to be achieved throug de creased maintenance costs and truck downtime as well as eli mmating the cost of gasoline and oil req'aired to operate a truck for 200.000 mi les in 10 vears. For example, it is esti mated that the additional cost of the combination PTO and battery-powered buck'.et truck now being produced can be amortized in about three years based s. oMv on the approximately -3500 per vea r in savings achieved bv decreasing r, iainte.na.nce costs. ELECTRIC v e h ic l e s g e t p r o d u c t io n g o -a h e a d I new- stimulus to electric vehicle proJuction has been provided by a group 0f 55 electric utilities. Funding a $1 million research program, the utilities h3ve ordered 100 on-the-road vehicles [or practical testing. The program is being sponsored by the Electric Vehicle Council (EVC), an operation of the Electric Energy Assoc., \ew York. Battronic Corp., division of Boverton Auto Body Works, Boyerton, pa., will build the trucks. Electric road vehicles will begin to appear in the US in noticeable numbers about 1980 according to EVC officials, in describing the 100-vehicle project, a program designed to help utilities un derstand use patterns of electrical ve hicles and the special requirements such vehicles may place on future power supply systems. The 55 utility companies plan to op erate the vehicles as general purpose, multi-stop work vehicles. Production will begin early in 1973 with first deliveries scheduled for March. Each vehicle wii be instrumented and careful records kept of its operations. These data should provide guidelines for the utilities in anticipating load demands and opera tion requirements of the 1980's. Unlike many earlier electrics, the Battronic is being designed from the wheels up and is not a converted pas senger car. According to Paul Hater. L Battronic president, the vehicle is des igned as a walk-in, van-type multistop w -Inch will be used for repair work, m eter reading, product distribution and pe Tsonnel transportation. It will carrv * 11000 lb. payload in a 140 cu. ft. cargo sps ice. It will weigh 6000 lb. and will has> 'e cargo area access from side doors ;wnii a rear door. General Electric Co. wiili provide the powerplant and a rmrtri -bed solid state controller. Lewi iagjlnas ^wnrrt: frrnin Ayrrwric.an Ceramic Society Suilatam 3* yaw*'!. on subject of lead teas hssbrrg am ceramic dmnerware S-C9giazas. Oiwts an* tables. Twelve pages. Lead a nmjpr flat (or in new machinery rase suppression systems ^esenalaan' off techniques used to lower mracfnuiH"^ miis e levels with lead and lead acmqinttM Uf.ts machines that normally 9*CMdi mrs* level allowed by Walsh- lr PUiaiic Contracts Act. Two pages. Liflt iutfh tf'.ectrically l^hiviitB a- erformance data on electric bather* aa wered vehicles for industrial us Cttr' calculators are designed to help biLvtar as cimate depreciation, operating L-Mamt -rraip itenance costs. Sixteen pages. id plenum barriers Qatari* d description of acoustical plenum tram* ^ and now to install them. Mate- md installation procedures described art* i Mustrated. Eight pages. J-10 Teefie liques for reducing machinery * iise ^ `print from Pollution Engineering details rr materials and solutions for reducing mar .hmery noise to acceptable levels. Spe cifics given for several machine types in common usage. Illustrated. Four pages. J-ll Controlling sound with lead Reprint cites three installations where lead is being used as a noise and vibra tion barrier: John Hancock Building: Baldwm-Wallace College; and New Eng land Medical Center, Boston. Four pages. J -12 Lead and zinc: Free world supply and demand 1972-5 Reprint of papers delivered at joint Lead and Zinc Associations Annual Meeting, April 1972. Statistical analysis, with charts, of factors influencing supply and demand of these metals through 1975. Twenty-five pages. M-10 Ecology in the new lead belt Reprint describes cooperation of industry and environmentalists in developing southern Missouri lead mines. Four pages. M-23 Waterproofing with sheet lead A description of the use of lead as a membrane wattfp roofing material for lin ing pools, plant , fountains, shower stalls and floors where positive water proofing is requir ad. Architectural details and speeificatior s are included. Eight pages. A-2 lead roofing and fashing Detailed instruct ons an the simplest and most usual met! for forming or join ing lead for re* ifmg and flashing appli cations. Compf ete specifications. Dia grammatic draw wigs. Sixteen pages. A-5 PAINTS Follow the safet j line with chrome yellow Formulations a nd suggested applications for chrome yi Mom safety paints. Illus trated. Eight pi i^l F-5 Red lead baser I paint i|ilin Provides detai on guwiid properties and suggested us. es of raonmended paints. Instructions c m surface preparation for * variety of a ppPeataens. Listing of LIA recommendet I formulahons. Thirty-two pages. F-l PLUMB1NC i Lead plumbi ag specificat im detatfs fir the use of connection, i and chemical lab- Four pages CHEMIC; U. CONSTRUCTION & CORROSJON PROTECTION A primer on the lead-acid battery A condensed story of the principles of the lead-acid battery and its chemistry, in cluding some of the fundamentals and definitions of direct-current electric en ergy. Two pages. L-fi Electric trucks are the choice Reprint from Electrified Industry, Opera tional and maintenance experience of a major company with battery powered inplant vehicles. Four pages. L-1G CERAMICS Facts about lead glazes for art potters and hobbyists Detailed information on the proper formu lation. firing techniques, handling, etc. of lead fluxed glazes used by art potters and hobby ceramists. Illustrated. Sixteen pages. B-ll SOUND BARRIERS Directory of acoustic specialties Summary of available materials for sound insulation by barrier, damping and absorption methods. Sixteen page list of materials by brand name and manufac turer. Eighteen pages. J-4 ANTI-VIBRATION PADS Ways to reduce press vibration Two installations of lead asbestos pads to reduce heavy machinery vibrations. Sec tional drawings and loadings are given. Two pages, illustrated. *1 Lead asbestos anti-vibration pads Specifics on lead anti-vibration pads in cluding design and sizing, specifications for the sub-contractor, and list of pad manufacturers. Three pages. G-l CABLE SHEATHING Lead-covered underground cable use increasing Reprint outlining a major utility's recent experience with lead sheathed under ground cable. Details on where this type cable is desirable. Graphs. Four pages. C-2 Lead Welding Reprint from American We/tfi*. Handbook, covers --** lead, joint desig and welding speeds, safety promotions tions- Bibliography. Fourteen"^|fi^ The U.S. Lead Industry--1971 An annual review of activity withi* dustry that contains a general for the year and a series of tables giving current statistics production and consumption. M-ls* S Primary lead production areas in the U.S. For schools, libraries. U'xH* m ing locations in U.S. of most lead jVS and refineries, and lead mines, Lead--A modern design matinji Summary of properties and forms of lead for radiation sound/vibration control, electncu* sources, soldering and ceram,!. * pages. M-15 The new lead belt Reprint of article details operatkxwj new lead belt in Missouri. Soe * scribes activities at four mines, h. centrators and three smelters, i pages. M-16. 1 Use of lead in the automobile Reprint of article from We/a/j i cussing in detail the various t_ tions of lead in the automobhl pages. M-17 1 Lead--The "Clydesdale" worth* in space Reprtnt from Space World detail applications of lead in space ups illustrated. Four pages. M-19. FILMS Lead Matrix A 26-min., 16mm color strates that lead <s one of the \ ments in the matrix that binds o zation together. To order, specify g show date and one alternate t ~ charge to borrow; viewer pays i turn postage. N-l This magazine is reproduced from lea 4 PRINTED IN U.S.A.